Sand casting

Overview
• Sand casting is a process where molten metal is cast in a mold made
from a sand mixture.
• In the past, the process was cost effective only for small volume
production. But nowadays it is also suitable for high volume production
thanks to automated equipment for making sand molds.
• Sand castings generally have a rough surface sometimes with surface
impurities, and surface variations. Medium to large parts such as valve
bodies, crankshafts and engine blocks are typically manufactured by this
process.
• The dimensional accuracy and surface finish of the casting depend on
the type of sand and the molding process.
Classification
• There are two main types of sand used for moulding: green sand and
dry sand.
• Green sand consists of silica sand, clay, moisture and other additives.
• Dry sand is a mixture of sand and fast curing adhesive.
• When dry sand is used, it is often referred to as no bake mould casting
or air set sand casting.
• Castings made from coarse green sand typically have a rough surface
whilst air-set moulds can produce castings with much smoother
surfaces.
Schematic showing the sand casting process.
Pattern

Pattern Types; (a) solid pattern, (b) split pattern, (c) match-
plate pattern, (d) cope and drag pattern
Pattern
• (a) Solid Pattern: made of one piece, adjusted in size for shrinkage and
machining, limited to very low production quantities.
• (b) Split Patterns: consist of two pieces, appropriate for complex parts
and moderate production quantities.
• (c) Match-Plate Patterns: two pieces of the split pattern are attached to
opposite sides of a wood or metal plate, used for higher production
quantities.
• (d) Cope and Drag Patterns: s are similar to match-plate patterns except
that split pattern halves are attached to separate plates, , so that the
cope and drag sections of the mold can be fabricated independently,
instead of using the same tooling for both.
Core

(a) Core held in place in the mold cavity by chaplets, (b)

possible chaplet design, and (c) casting with internal cavity.
Quality of sand mold
Several indicators are used to determine the quality of the sand mold:
(1)strength— the mold’s ability to maintain its shape and resist erosion caused by the flow of
molten metal; it depends on grain shape, adhesive qualities of the binder, and other factors;
(2) permeability—capacity of the mold to allow hot air and gases from the casting operation
to pass through the voids in the sand;
(3)thermal stability—ability of the sand at the surface of the mold cavity to resist cracking
and buckling upon contact with the molten metal;
(4) collapsibility—ability of the mold to give way and allow the casting to shrink without
cracking the casting; it also refers to the ability to remove the sand from the casting during
cleaning; and
(5)reusability—can the sand from the broken mold be reused to make other molds? These
measures are sometimes incompatible; for example, a mold with greater strength is less
collapsible.
Shell-Mold Casting:
Shell-Mold Casting:
• 1- The two pieces pattern (match-plate or cope and drag) is made of
metal (e.g. aluminum or steel), it is heated to (175-370ºC) and coated
with a lubricant, e.g. silicone spray.
• 2- The dump box (which contains a sand) and pattern is inverted many
times to generate the sand shell onto the pattern.
• 3- Each heated half-pattern is covered with a mixture of sand and a
thermoset resin/epoxy binder. The binder glues a layer of sand to the
pattern, forming a shell. The process may be repeated many time to
get a thicker shell.
Shell-Mold Casting:
• 4- The assembly is baked into oven to cure it.
• 5- The patterns are removed and the shell molds are generated.
• 6- The two half-shells are joined together by a clamp to form the mold
and supported by sand or metal shot in a flask. The molten metal is
poured into the mold.
• 7- The shell is broken to get the final casting.